Grooved insulator to reduce leakage current Patent Grant Cho , et al. May 23, 2 [Applied Materials, Inc.]

Grooved insulator to reduce leakage current

Cho , et al. May 23, 2

Patent Grant 9659753

U.S. patent number 9,659,753 [Application Number 14/454,493] was granted by the patent office on 2017-05-23 for grooved insulator to reduce leakage current. This patent grant is currently assigned to Applied Materials, Inc.. The grantee listed for this patent is Applied Materials, Inc.. Invention is credited to Nicholas Celeste, Tae Cho, Peter Hillman, Sang Won Kang, Raymond W. Lu, Dmitry Lubomirsky, Soonam Park, Tien Fak Tan, Dongqing Yang.

United States Patent	9,659,753
Cho , et al.	May 23, 2017

Grooved insulator to reduce leakage current

Abstract

A plasma source includes a first electrode and a second electrode having respective surfaces, and an insulator that is between and in contact with the electrodes. The electrode surfaces and the insulator surface substantially define a plasma cavity. The insulator surface defines one or more grooves configured to prevent deposition of material in a contiguous form on the insulator surface. A method of generating a plasma includes introducing one or more gases into a plasma cavity defined by a first electrode, a surface of an insulator that is in contact with the first electrode, and a second electrode that faces the first electrode. The insulator surface defines one or more grooves where portions of the insulator surface are not exposed to a central region of the cavity. The method further includes providing RF energy across the first and second electrodes to generate the plasma within the cavity.

Inventors:

Cho; Tae (San Jose, CA), Kang; Sang Won (Cupertino, CA), Yang; Dongqing (San Jose, CA), Lu; Raymond W. (San Francisco, CA), Hillman; Peter (Santa Clara, CA), Celeste; Nicholas (Oakland, CA), Tan; Tien Fak (Campbell, CA), Park; Soonam (Sunnyvale, CA), Lubomirsky; Dmitry (Cupertino, CA)

Applicant:

Name	City	State	Country	Type
Applied Materials, Inc.	Santa Clara	CA	US

Assignee:

Applied Materials, Inc. (Santa Clara, CA)

Family ID:

55267938

Appl. No.:

14/454,493

Filed:

August 7, 2014

Prior Publication Data


	Document Identifier	Publication Date
	US 20160042920 A1	Feb 11, 2016

Current U.S. Class:	1/1
Current CPC Class:	H01J 37/3255 (20130101); H01J 37/32082 (20130101)
Current International Class:	H01J 37/32 (20060101)

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Primary Examiner: Taningco; Alexander H
Assistant Examiner: Correa; Nelson
Attorney, Agent or Firm: Kilpatrick Townsend & Stockton LLP

Claims

We claim:

1. A plasma source, comprising: a first electrode and a second electrode, the first and second electrodes comprising first and second electrode surfaces respectively; and an insulator, comprising an insulator surface, disposed between and in contact with the first and second electrodes, wherein: the first and second electrode surfaces and the insulator surface substantially define a plasma cavity; the insulator forms a shoulder portion that is in contact with the second electrode surface, and a vertically recessed portion that is disposed axially inward with respect to the shoulder portion but is not in contact with the second electrode surface; the insulator surface defines one or more grooves configured to prevent deposition of material in a contiguous form on the insulator surface exposed to the plasma cavity; and the one or more grooves are vertical grooves formed within the vertically recessed portion.

2. The plasma source of claim 1, wherein: the second electrode surface is an upwardly facing, round and substantially planar surface where it contacts the insulator; the insulator is substantially cylindrical, and is disposed atop and axially aligned with the second electrode surface, such that the insulator surface is an axially inwardly facing surface; and the first electrode is disposed atop the insulator.

3. The plasma source of claim 1, wherein the insulator comprises ceramic.

4. The plasma source of claim 1, wherein at least one of the first and second electrodes comprises aluminum.

5. The plasma source of claim 4, wherein the aluminum is plated with nickel or an alloy thereof.

6. The plasma source of claim 1, wherein the one or more grooves is a single groove.

7. The plasma source of claim 1, wherein the one or more grooves are a plurality of grooves.

8. The plasma source of claim 1, wherein at least one of the one or more grooves comprises a rectilinear profile.

9. A method of manufacturing a plasma source, comprising: forming ceramic material into a green body having a shape of an insulator, with one or more grooves formed in the green body; sintering the green body to form the insulator; disposing an insulator, with one or more grooves defined in an insulator surface thereof, in contact with a first electrode; disposing a second electrode in contact with the insulator to form a cavity that is bounded by a surface of the first electrode, a surface of the second electrode, and the insulator surface; providing an inlet gas line configured to introduce one or more gases into the cavity through at least one of the first electrode and the second electrode; and providing an electrical coupling across the first and second electrodes, wherein: the first and second electrodes are isolated from electrically contacting one another, by the insulator; the cavity is configured such that when the one or more gases are introduced into the cavity and the electrical coupling provides RF energy across the first and second electrodes, a plasma forms within the cavity; and the one or more grooves defined in the insulator surface are configured such that deposition of plasma sputtered material from the first or second electrode surfaces on the insulator surface is interrupted at the one or more grooves.

10. The method of manufacturing a plasma source of claim 9, wherein forming the ceramic material into the green body having the shape of the insulator comprises casting the one or more grooves into the shape of the insulator.

11. The method of manufacturing a plasma source of claim 9, wherein forming the ceramic material into the green body having the shape of the insulator comprises: casting ceramic material into the green body having the shape of the insulator, without the one or more grooves; and machining the one or more grooves into the green body.

12. A method of manufacturing a plasma source, comprising: forming ceramic material into a green body having a shape of an insulator; sintering the green body to form the insulator; machining the insulator to form one or more grooves in an insulator surface thereof, disposing the insulator in contact with a first electrode; disposing a second electrode in contact with the insulator to form a cavity that is bounded by a surface of the first electrode, a surface of the second electrode, and the insulator surface; providing an inlet gas line configured to introduce one or more gases into the cavity through at least one of the first electrode and the second electrode; and providing an electrical coupling across the first and second electrodes, wherein: the first and second electrodes are isolated from electrically contacting one another, by the insulator; the cavity is configured such that when the one or more gases are introduced into the cavity and the electrical coupling provides RF energy across the first and second electrodes, a plasma forms within the cavity; and the one or more grooves defined in the insulator surface are configured such that deposition of plasma sputtered material from the first or second electrode surfaces on the insulator surface is interrupted at the one or more grooves.

Description

TECHNICAL FIELD

The present disclosure is in the field of plasma processing equipment. More specifically, embodiments that reduce undesirable leakage and/or electrical discharge effects among certain components are disclosed.

BACKGROUND

In plasma processing, plasmas create ionized and/or energetically excited species for interaction with workpieces that may be, for example, semiconductor wafers. To create and/or maintain a plasma, one or more radio frequency (RF) and/or microwave generators typically generate oscillating electric and/or magnetic fields. In some wafer processing systems, a plasma is generated in the same location as one or more wafers being processed; in other cases, a plasma is generated in one location and moves to another location where the wafer(s) are processed. The plasmas produced often contain highly energetic and/or corrosive species and/or highly energetic electrons, such that the equipment that produces them sometimes degrades from contact with the energetic species and/or electrons. For example, materials that are exposed to highly energetic species may be etched and/or sputtered, generating etched and/or sputtered material that can move about, and can react or deposit on various surfaces.

SUMMARY

In an embodiment, a plasma source includes a first electrode and a second electrode having respective first and second electrode surfaces, and an insulator having an insulator surface that is between and in contact with the first and second electrodes. The first and second electrode surfaces and the insulator surface substantially define a plasma cavity. The insulator surface defines one or more grooves configured to prevent deposition of material in a contiguous form on the insulator surface exposed to the plasma cavity.

In an embodiment, a method of manufacturing a plasma source includes placing an insulator, with one or more grooves defined in a surface thereof, in contact with a first electrode, and placing a second electrode in contact with the insulator to form a cavity that is bounded by a surface of the first electrode, a surface of the second electrode, and a surface of the insulator. An inlet gas line is configured to introduce one or more gases into the cavity through at least one of the first electrode and the second electrode. An electrical coupling is provided across the first and second electrodes. The first and second electrodes are isolated from electrically contacting one another, by the insulator. The cavity is configured such that when the one or more gases are introduced into the cavity and the electrical coupling provides RF energy across the first and second electrodes, a plasma forms within the cavity. The one or more grooves in the insulator surface are configured such that deposition of plasma sputtered material from the first or second electrode surfaces on the insulator surface is interrupted at the one or more grooves.

In an embodiment, a method of generating a plasma includes introducing one or more gases into a plasma cavity. The cavity is defined by a substantially planar surface of a first electrode, an insulator surface of an insulator that is in contact with the first electrode along at least a portion of the planar surface. The insulator forms a central opening, such that a portion of first electrode that faces the central opening is not in contact with the insulator. A second electrode faces the first electrode through the central opening, the second electrode being in contact with the insulator about the central opening. The first and second electrodes are electrically isolated from one another by the insulator. The cavity is bounded by the substantially planar surface of the first electrode, a surface of the second electrode, and the insulator surface. The insulator surface defines one or more grooves such that at the grooves, portions of the insulator surface are not exposed to a central region of the cavity. The method further includes providing RF energy across the first and second electrodes to generate the plasma within the cavity.

Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating various embodiments, are intended for purposes of illustration only and are not intended to necessarily limit the scope of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be understood by reference to the following detailed description taken in conjunction with the drawings briefly described below, wherein like reference numerals are used throughout the several drawings to refer to similar components. It is noted that, for purposes of illustrative clarity, certain elements in the drawings may not be drawn to scale. In instances where multiple instances of an item are shown, only some of the instances may be labeled, for clarity of illustration.

FIG. 1 schematically illustrates major elements of a plasma processing system, according to an embodiment.

FIG. 2 schematically illustrates major elements of a plasma processing system, in a cross-sectional view.

FIG. 3 schematically illustrates a region noted in FIG. 2, again in a cross-sectional view.

FIG. 4 schematically illustrates a region noted in FIG. 3, again in a cross-sectional view.

FIG. 5 schematically illustrates a region noted in FIG. 3, again in a cross-sectional view, with an insulator buildup acting as a charge trap.

FIG. 6 illustrates a representative waveform of a discharge event within a plasma source.

FIG. 7 is a photograph of a diffuser removed after discharge events were noted in a plasma source.

FIG. 8 schematically illustrates a similar region as shown in FIGS. 2 and 3, with horizontal grooves in an insulator, according to an embodiment.

FIG. 9 schematically illustrates a region shown in FIG. 8, after operation that results in a buildup.

FIG. 10 schematically illustrates a similar region as shown in FIGS. 2 and 3, with vertical grooves in an insulator, according to an embodiment.

FIG. 11 schematically illustrates a region shown in FIG. 10, after operation that results in a buildup.

FIG. 12 schematically illustrates grooves having rounded ends within an insulator in a region that corresponds to a region shown in FIGS. 8-9, according to an embodiment.

FIG. 13 schematically illustrates a single groove having a non-rectilinear profile within an insulator in a region that corresponds to a region shown in FIGS. 8-9, according to an embodiment.

Additional embodiments and features are set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the invention. The features and advantages of the invention may be realized and attained by means of the instrumentalities, combinations, and methods described in the specification.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates major elements of a plasma processing system 100, according to an embodiment. System 100 is depicted as a single wafer, semiconductor wafer plasma processing system, but it will be apparent to one skilled in the art that the techniques and principles herein are applicable to plasma generation systems of any type (e.g., systems that do not necessarily process wafers or semiconductors). Processing system 100 includes a housing 110 for a wafer interface 115, a user interface 120, a plasma processing unit 130, a controller 140 and one or more power supplies 150. Processing system 100 is supported by various utilities that may include gas(es) 155, external power 170, vacuum 160 and optionally others. Internal plumbing and electrical connections within processing system 100 are not shown, for clarity of illustration.

Processing system 100 is shown as a so-called indirect plasma processing system that generates a plasma in a first location and directs the plasma and/or plasma products (e.g., ions, molecular fragments, energized species and the like) to a second location where processing occurs. Thus, in FIG. 1, plasma processing unit 130 includes a plasma source 132 that supplies plasma and/or plasma products for a process chamber 134. Process chamber 134 includes one or more wafer pedestals 135, upon which wafer interface 115 places a workpiece 50 (e.g., a semiconductor wafer, but could be a different type of workpiece) for processing. In operation, gas(es) 155 are introduced into plasma source 132 and a radio frequency generator (RF Gen) 165 supplies power to ignite a plasma within plasma source 132. Plasma and/or plasma products pass from plasma source 132 through a diffuser plate 137 to process chamber 134, where workpiece 50 is processed.

Although an indirect plasma processing system is illustrated in FIG. 1 and elsewhere in this disclosure, it should be clear to one skilled in the art that the techniques, apparatus and methods disclosed herein are equally applicable to direct plasma processing systems--e.g., where a plasma is ignited at the location of the workpiece(s)--and other systems, that utilize insulators that may be subjected to accumulation of contaminants.

FIG. 2 schematically illustrates major elements of a plasma processing system 200, in a cross-sectional view, according to an embodiment. Plasma processing system 200 is an example of plasma processing unit 130, FIG. 1. Plasma processing system 200 includes a process chamber 205 and a plasma source 210. As shown in FIG. 2, plasma source 210 introduces source gases, via an inlet gas line 222 that connects through a gas passage 234 in an insulator 230, to an inlet port 215 and a nozzle 220 that are formed in an RF electrode 225. Insulator 230 electrically insulates RF electrode 225 from a diffuser 235 that is held at electrical ground. RF electrode 225 and diffuser 235 may be formed of any conductor, and in embodiments are formed of aluminum (or an aluminum alloy, such as the well-known "6061" alloy type) that is plated with nickel or an alloy thereof. Insulator 230 may be any insulator, and in embodiments is formed of ceramic. Surfaces of RF electrode 225, diffuser 235 and insulator 230 define a plasma cavity (see plasma cavity 240, FIG. 3). RF electrode 225, diffuser 235 and insulator 230 are substantially radially symmetric in the embodiment shown in FIG. 2. Thus, diffuser 235 forms an upwardly facing, round and substantially planar surface (236, see FIG. 3) where it contacts insulator 230; insulator 230 is substantially cylindrical, disposed atop and axially aligned with respect to the upper surface of diffuser 235, with one axial end in contact with diffuser 235. RF electrode 225 is disposed atop insulator 230.

In the context of the present disclosure, the presence of gas passage 234, or other passages or local features within insulator 230, and the widening of insulator 230 that allows it to fit atop other components, do not change the shape of insulator 230 from being "substantially cylindrical" as used herein. Similarly, apertures 237 allow plasma products to exit plasma 250; apertures 237 do not alter surface 236 of diffuser 235 from being "substantially planar" as used herein. Diffuser 235 may have other features such as a surface offset or mating structure where it contacts insulator 230, that would similarly not alter surface 236 from being "substantially planar" as used herein. In other embodiments, electrodes and insulators may not necessarily be radially symmetric, and may be shaped and/or disposed in orientations other than that shown in FIG. 2 (e.g., plasma cavity 240, FIG. 3, may not be shaped or oriented as shown). Plasma and/or plasma products pass through apertures 237 formed in diffuser 235 toward process chamber 205. A region denoted as A is shown in greater detail in FIG. 3.

FIG. 3 schematically illustrates region A noted in FIG. 2, again in a cross-sectional view. RF electrode 225 forms a first electrode surface 226; insulator 230 forms an insulator surface 232 that is oriented axially inward. Diffuser 235 forms a second electrode surface 236. First electrode surface 226, second electrode surface 236 and insulator surface 232 substantially define a plasma cavity 240, where a plasma 250 forms when gases are introduced through inlet gas port into nozzle 220 and RF power is applied to RF electrode 225 (the shape of plasma 250 that is depicted in FIG. 3 is not intended to represent an actual boundary of plasma 250 but shows approximately where plasma 250 is generated). Plasma 250 may interact with surfaces of RF electrode 225, insulator 230 and diffuser 235, for example energetic species may bombard these surfaces and may sputter material from them. A region denoted as B is shown in even greater detail in FIGS. 4 and 5. A point X is defined as being centered with respect to insulator 230 and midway from diffuser 235 and RF electrode 225, and may be regarded as an average point of origin for material sputtered from surfaces within plasma cavity 240, as discussed further in connection with FIGS. 9 and 11.

FIG. 4 schematically illustrates region B noted in FIG. 2, again in a cross-sectional view. When plasma 250 is generated in plasma cavity 240, material may sputter from RF electrode 225 and/or diffuser 235; some of the material sputtered from these surfaces may accumulate on surface 232 of insulator 230 as buildup 245.

Buildup 245 may act as a leakage path and/or floating electrode between RF electrode 225 and diffuser 235. When buildup 245 becomes thick enough to act as a conductor along a portion of insulator 230, potential differences between RF electrode 225 and diffuser 235 are not uniformly distributed across insulator 230; instead, such potential differences are confined to the gaps between buildup 245 and each of RF electrode 225 and diffuser 235, increasing surface leakage and/or electrical arcing across these gaps.

Buildup 245 can also act as a charge trap. FIG. 5 schematically illustrates region B noted in FIG. 2, again in a cross-sectional view, with an insulator buildup 245 acting as a charge trap. Plasma 250 generates electrons, among other plasma products, and plasma 250 interacts with surfaces within plasma cavity 240, sometimes sputtering material from exposed surfaces, which may also carry charge. Charges 255 can accumulate within buildup 245 and discharge from time to time to RF electrode 225, diffuser 235 or both, as suggested by arrow 249. Discharge is especially likely when surface 232 extends very close to surface 236, such that a high electric field is caused by charges 255 within buildup 245 across the small distance between surfaces 232 and 236.

Discharges and/or leakage paths among buildup 245, RF electrode 225 and diffuser 235 can be highly detrimental to processing, because generating a uniform plasma for processing strongly depends on uniform electrical field and power distributions within plasma cavity 240. When discharges occur, power can be diverted and/or plasma 250 can become strongly distorted, disrupting the amount and uniformity of plasma and/or plasma products available to pass through diffuser 235 and on to process chamber 205. Discharges can also damage RF electrode 225, insulator 230 and/or diffuser 235, which may alter or destroy the ability of plasma source 210 to deliver suitable plasma and/or plasma products at all. Alternatively, buildup 245 can form a persistent leakage path that leaks current between RF electrode 225 and diffuser 235 through a resistive connection. The current leakage distorts the oscillating electrical field across the plasma cavity and again prevents plasma source 210 from operating as designed.

When buildup 245 acts as either of a floating electrode or leakage path, excessive power is required to sustain plasma 250, and the plasma and/or plasma products provided through diffuser 235 are decreased and nonuniform. The nonuniformity of the plasma and/or plasma products leads to nonuniform processing across process chamber 205. In such cases, when process chamber 205 is utilized for plasma etching, the etch rate becomes nonuniform across an etched wafer and the average etch rate decreases, affecting throughput of the processing system (wafers must be etched longer) and lowering yield of wafers processed therein. That is, some parts of the wafer are under-etched, as compared to other parts of the wafer, and may have unacceptably altered electrical characteristics such that integrated circuits fabricated in the under-etched parts of the wafer are scrapped).

FIG. 6 shows a representative oscilloscope trace 500 obtained before, during and after a discharge event within plasma source 210. In oscilloscope trace 500, measured voltage and current are on the vertical axis, with time on the horizontal axis. A waveform of voltage applied to RF electrode 225, FIG. 2, generates a relatively smooth, somewhat sinusoidal waveform 510; the alternating current ("AC") voltage indicated by waveform 510 is about 300V (root mean square or "RMS"). The current discharged through RF electrode 225 is shown in a waveform 520 that is similar in phase but is less regular. A discharge event occurs over the approximate time period identified as time period 530. During time period 530, charge that has built up on insulator 230 discharges to diffuser 235, reducing the current that is measured in waveform 520. Feedback effects cause voltage waveform 520 to vary for a couple of cycles during and after the discharge event.

FIG. 7 is a photograph of a diffuser 235 removed after discharge events were noted in a plasma source 210. FIG. 7 shows small holes in a Ni coating of diffuser 235 at locations indicated by arrows. The diffuser shown in FIG. 7 was removed from a plasma source 210 in which discharges were observed, and in which plasma processing uniformity was known to be impaired.

FIG. 8 schematically illustrates a similar region as region A (FIGS. 2, 3) now denoted as A', wherein insulator 230' forms horizontal grooves adjacent to plasma cavity 240. In FIG. 8, RF electrode 225 and diffuser 235 are identical to the same elements as shown in FIGS. 2, 3 and 4, but an insulator 230' forms horizontal grooves 260 in the location of surface 232 as shown in FIGS. 3, 4. Grooves 260 interfere with deposition of buildup (e.g., buildup 245, FIG. 4) on insulator 230' as compared with insulator 230. Because atoms that are sputtered from surfaces tend to travel in straight paths, the geometry created by grooves 260 interferes with creation of a buildup layer that is contiguous across grooves 260, decreasing the likelihood of such buildup being able to provide a leakage and/or discharge path between RF electrode 225 and diffuser 235. The three grooves 260 shown are exemplary only; in embodiments, any number, shape and/or orientation of grooves may be utilized. A region denoted as C is shown in detail in FIG. 9.

FIG. 9 schematically illustrates region C, FIG. 8, after operation that results in a buildup 245'. Material that is sputtered from surfaces facing plasma cavity 240 (primarily surfaces 226 and 236, FIGS. 3 and 4) travels in a general direction indicated by arrow 242. Not all such material will travel in exactly the same direction, but material that is sputtered from one electrode surface and lands on another such surface need not be considered. Generally, the material that could form buildup 245, 245' travels in a radial direction from a central region of plasma cavity 240 toward insulator 230. In one embodiment, a point that is central to insulator 230, and midway between diffuser 235 and RF electrode 225 (e.g., point X, FIG. 3) may be regarded as an average point of origin of sputtered material, such that insulator surfaces that are not exposed to this point will not generate buildup 245, 245'. The sputtered material generally adheres to the first surface that it strikes, resulting in buildup 245' as shown, which is interrupted, for example, at locations 248. The interruptions in buildup 245' promote plasma uniformity by minimizing discharge and/or leakage paths between RF electrode 225 and diffuser 235. Thus, at least grooves 260-1 and 260-2 provide surfaces that are not exposed to the central region of plasma cavity 240 (or at least to point X) such that buildup 245' will not be contiguous over these surfaces. Groove 260-2 may also defeat contiguous buildup 245'. The walls of groove 260-2 will at least present a topology that is unlikely to be covered with a contiguous buildup of material sputtered in the direction of arrow 242; the geometry shown will be familiar to those skilled in the art of semiconductor processing as providing a "step coverage" problem.

FIG. 10 again schematically illustrates a similar region as region A (FIGS. 2, 3), now denoted as A''. In FIG. 10, RF electrode 225 and diffuser 235 are identical to the same elements as shown in FIGS. 2 through 5, but insulator 230 is replaced by an insulator 230'' that has vertical grooves 270 on an underside of insulator 230 (near surface 232 as shown in FIGS. 3-5). Grooves 270 interfere with deposition of buildup (e.g., buildup 245, FIG. 4) on insulator 230'' as compared with insulator 230, by interrupting line-of-sight deposition of material sputtered from surfaces of plasma cavity 240 that are exposed to plasma 250. Insulator 230'' is recessed above diffuser 235 in the region of grooves 270 to avoid damage to insulator 230'' against diffuser 235. A shoulder 275 of insulator 230'' is more mechanically robust than the recessed portion 272 of insulator 230'' in the area of grooves 270, therefore shoulder 275 rests against diffuser 235. Like grooves 260 in insulator 230', grooves 270 interrupt line-of-sight deposition of material sputtered from surfaces of plasma cavity 240 that are exposed to plasma 250, such that if a buildup layer forms, it is not contiguous across grooves 270. Again, the three grooves shown are exemplary only; in embodiments, any number, shape and/or orientation of grooves may be utilized. A region denoted as D is shown in detail in FIG. 11.

FIG. 11 schematically illustrates region D, FIG. 10, after operation that results in a buildup 245''. Material that is sputtered from surfaces facing plasma cavity 240 (primarily, surfaces 226 and 236, FIGS. 3 and 4) travels in a general direction indicated by arrow 242. The sputtered material results in buildup 245'' as shown, which is interrupted at locations 248'. The interruptions in buildup 245'' promote plasma uniformity by minimizing discharge and/or leakage paths between RF electrode 225 and diffuser 235.

The use of grooves in insulators in embodiments herein is different from the practice of providing insulators with topology variations, as is found for example in insulators for very high voltage equipment. In typical high voltage equipment, even clean surfaces (e.g., with no unwanted buildup or contamination) can behave differently from bulk material, for example by providing surface leakage paths. Therefore when conductors having a high voltage difference (e.g., with DC voltages and/or instantaneous AC voltage peaks in the range of 10 kV or more) are separated by an insulator, it is advantageous to simply increase the surface path across the insulator from one conductor to the other. In such cases, the increased surface path need not have any particular geometry. By contrast, the plasma sources herein operate at much lower voltages (e.g., <5 kV AC RMS, often <500V AC RMS, with instantaneous voltage peaks <1000V), and the grooved insulators interrupt line-of-sight deposition from sputtering sources. That is, grooves in embodiments herein increase surface paths only slightly but are effective because they prevent a contiguous buildup from forming. "AC" and "RMS" as used herein have their well-known meanings in the electrical arts of "alternating current" and "root mean square" respectively. In embodiments, plasma sources may operate around 300V AC RMS.

One or more grooves may be formed into insulators such as insulators 230', 230'' in a variety of ways. For example, grooves may be simply pressed into raw ceramic material, for example as a ceramic particle slurry is first formed into a green body (e.g., before the body is sintered to harden the green body into the final ceramic structure). Alternatively, the grooves may be machined into a green ceramic body. Machining the grooves into the green ceramic body may be advantageous in that some grain consolidation and growth occurs during sintering, roughening the surface such that material sputtered thereon is less likely to form a contiguous buildup. Alternatively, grooves may be machined into an insulator after firing, during a final machining step. Grooves may be formed with rectilinear profiles as illustrated in FIGS. 8-11, or may form different profiles. Grooves may be formed at approximately 90 angles to the surfaces of an insulator, as shown, or at other angles, for ease of manufacturing and/or to form surfaces that can best interrupt buildup of sputtered material for a given plasma source geometry.

Grooves may also be formed into insulators in multiples, shapes and orientations other than those shown in FIGS. 8-11. FIG. 12 schematically illustrates a region C' corresponding to region C, FIGS. 8-9. In FIG. 12, an insulator 630 forms two grooves 660 that are slots formed at an angle with respect to a surface of insulator 630. Grooves 660 have rounded ends. FIG. 13 schematically illustrates a region D' corresponding to region D, FIGS. 10-11. In FIG. 13, an insulator 730 forms a single groove 760 that has a non-rectilinear profile. In the geometry illustrated in FIG. 13, a buildup 745 can occur on surface 732, but a recess height h of a recessed region 772 of insulator 730 can be chosen such that even when buildup 745 occurs, recess height h leads to an electric field strength that is insufficient to cause a current discharge from buildup 745 to surface 732. This may be contrasted to the arrangement shown in FIG. 4 wherein surface 232 extends to surface 236 (such that an electric field due to charges 255 is concentrated across a very small gap).

Specific details are given in the above description to provide a thorough understanding of the embodiments. However, it is understood that the embodiments may be practiced without these specific details. For example, well-known processes, structures, and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments. While the principles of the disclosure have been described above in connection with specific apparatuses and methods, it is to be clearly understood that this description is made only by way of example and not as limitation on the scope of the disclosure.

It is appreciated that the arrangements shown are exemplary only; other embodiments may differ greatly in configuration, including how source gases are introduced, how electrodes and insulators are arranged, how plasma and/or plasma products are handled after generation, and how grooves are formed in insulators. It is contemplated that the techniques and apparatus disclosed herein are applicable to these and other arrangements wherein conductive material builds up during use and thereby creates leakage and/or discharge paths.

As used herein and in the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a process" includes a plurality of such processes and reference to "the electrode" includes reference to one or more electrodes and equivalents thereof known to those skilled in the art, and so forth. Also, the words "comprise," "comprising," "include," "including," and "includes" when used in this specification and in the following claims are intended to specify the presence of stated features, integers, components, or steps, but they do not preclude the presence or addition of one or more other features, integers, components, steps, acts, or groups.

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